Building and training block and process for making

ABSTRACT

A process for making blocks with simulated masonry faces which involves forming individual building or training block shapes and applying a decorative arrangement of mortar lines on each block surface. The decorated surfaces are etched according to the decorative line arrangement and thereafter smoothed and finished to form finished blocks bearing simulated masonry faces. The product made by the process is also included as part of the invention.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to children's building and training blocksand, more particularly, to a process for making simulated masonry blocksfrom wood or other materials having etched continuous mortar lines andthe product made by the process.

2. Description of the Prior Art

Children's block sets have traditionally been used as toys when theinfants are small and have more recently been developed as sets toenhance learning in particular areas. Children learn by playing withblocks in accordance with a particular activity. Each activityencourages problem solving, enhances fine and gross motor development,the development of math, science, language and social skills. Specialblock shapes such as units, pillars, columns, circles, arches, trianglesand smaller specialized shapes are included in modern block sets, andactivities are outlined and illustrated for use with these sets. Blockscome in different colors, and they stimulate imaginations, buildcoordination skills, and encourage patterning and color matching. Theyusually are formed from wood or plastic and may be solid or hollow andare often provided in unit block sets.

The “unit” gin unit blocks has very special dimensions. The dimensionsof each block shape in a set of unit blocks is a multiple or fraction ofthe size of the piece designated the “unit”. The unit, in the usualembodiment, is a rectangular piece measuring 5½ inches in length by 2¾inches in width by 1⅜ inches in height or thickness. The name of eachbasic rectangular block in a set is based on its size as compared to thelength of the “unit, e.g., the unit block is 5½ inches long while thehalf unit block is 2¾ inches, the double unit block is 11 inches longand the quad unit block is 22 inches long. The dimensions of all otherblock shapes, including the columns, the pillars, the triangles, thecurves, etc., are proportional to the length, width and heightdimensions of the unit. The fixed dimensional relationship between theunit and the other block shapes creates an environment in which childrendevelop motor skills and absorb math concepts such as length, volume andfractions while totally engaged in the creative freedom of block play.Through play activities children discover the relationship between thedifferent standard unit block shapes and learn by playing, e.g.,discovering that 2 unit triangles make a unit block, two unit pillarsequal one unit block and so on. To summarize, the length of a unit isexactly twice the width, and the width is exactly twice the thickness.The other blocks are all multiples or divisions of the unit. Thus unitblock sets are modular.

When children play with blocks, they are practicing mathematical skills.In selecting blocks of different sizes and shapes and comparing surfacevolumes and areas, they are unwittingly using classification andseriation. Cleaning up involves math too: sorting identical anddissimilar shapes and organizing by size. Because it involves measuringlengths, widths and heights (if only by eye), block play develops achild's ability to mentally visualize relationships. Such manipulationsare similar to those used in geometry and algebra during the child'slater school years.

New forms of blocks are being formed from time to time, and the presentinvention is one of the new building and training block sets that havebeen created.

SUMMARY AND OBJECTIVES OF THE INVENTION

This application is directed to a process for making training orbuilding blocks with simulated masonry faces such as brick, stone andother common building materials and to the blocks made by the process.The process includes the steps of forming a block or wall section withone or more blocks from a larger piece of block material such as wood orplastic, applying a decorative arrangement of lines on the block or wallsection surfaces surfaces, routing, etching embossing or stamping thearrangement of lines to simulate mortar lines on the block or wallsection faces faces, smoothing the block or wall section faces withoutremoving the etched decorative arrangement of lines, and finishing theblock or wall section surfaces to form a finished block or wall sectionof simulated masonry faces on the unit block or wall section surfaces.The mortar lines displayed on all block surfaces extend consistently toadjacent block or wall section surfaces be they in the same block orwall or on separate but adjacent blocks or wall sections. Blocks may beof varying sizes but of complementing sizes on some separate blocksurfaces.

From the summary set forth above, it can be seen that a primaryobjective of the present invention is to provide a process for formingbuilding or training blocks With simulated masonry surfaces and thebuilding or training blocks made by the process.

Another objective of the present invention is to form simulated andetched block masonry surfaces to achieve a realistic surface design.

Yet another objective is to provide consistently matchable faces ofdifferent sized blocks or wall sections and consistently extended mortarlines to adjacent block and wall section surfaces.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of simulated brick building or trainingblocks used in a building block exercise;

FIG. 2 is a plan perspective view of a group of different blocks of aunit block set produced by the process of the present invention;

FIG. 3 is a plan perspective view of two pieces of a unit block setcombined to form yet another piece both of which are produced by theprocess of the present invention;

FIG. 4 is a front elevational perspective view of four pieces of a unitblock set combined in pairs of two's to form two additional differentpieces all produced by the process of the process of the presentinvention;

FIG. 5 is a block diagram setting forth the steps of the process formaking the training blocks of the present invention; and

FIG. 6 is a plan and perspective view of a variety, but not a completenumber, of block shapes that can be included in a unit block set made inaccordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings and particularly to FIG. 1, a child isundertaking a building project with a set of training blocks similar tothose produced by the process described hereinafter. The blocks aremodular in that a unit block 10 is being used with a number of doubleunit blocks 12. The blocks are being stacked to form a wall or perhaps abuilding side in the customary manner.

A unit block set made by the process of the present invention is shownin FIG. 2 generally as 14. Individual pieces include a unit 10, a doubleunit 12, triangles 16, a quad unit 18 and other assorted pieces allbeing multiples or divisions of the unit.

The production of building or training blocks like those describedincludes forming individual pieces from larger segments of the blockmaterial, preferable wood, into a number of individual pieces ofappropriate sizes to build a unit block set like that shown in FIG. 2 ora larger or smaller set so long as the unit of the set is maintained.After one or more block pieces are formed from the block of largermaterial, each piece is decorated with an arrangement of lines on one ormore surfaces of the piece simulating mortar lines. These lines are thenetched with an appropriate etching tool such as a router, grinder,stamper, embossor or burner to produce three dimensional grooves in thepiece surface to realistically form the simulated mortar lines byfollowing the arrangement of lines originally applied.

The block pieces and wall segments are then coated with an appropriatechild-friendly paint or stain preferably the color of natural coloredbrick. Once dried, the simulated mortar lines are painted or otherwisecovered with a mortar color such as grey or a grey-white blend so thatthe final block simulates individual parts of a unit block set.

The individual unit block pieces are formed with mortar lines preferablyon all faces so that all mortar lines of all pieces are compatible withthese lines on all other blocks. Thus when blocks are combined in abuilding project, the simulated mortar lines displayed on all unit blocksurfaces extend consistently to adjacent unit block surfaces therebyresulting in a very realistic model of a conventional brick wall orstructure.

As reflected in FIG. 6, a variety of unit block pieces are often used topermit more artistic parts or components to be included in a unitbuilding or training block project. Any number of such parts arepossible, it being only necessary to keep the modular concept consistentso that such blocks be multiples or divisions of the unit block.

Variations and modifications of the foregoing are within the scope ofthe present invention. It is understood that the invention disclosed anddefined herein extends to all alternative combinations of two or more ofthe individual features mentioned or evident from the text and/ordrawings. All of these different combinations constitute variousalternative aspects of the present invention. The embodiments describedherein explain the best modes known for practicing the invention andwill enable others skilled in the art to utilize the invention. Theclaims are to be construed to include alternative embodiments to theextent permitted by the prior art, and various features of the inventionare set forth in the following claims.

1. A process of making building and training blocks having simulatedmasonry faces comprising the steps of: forming a block segment havingone or more surfaces from a larger segment of material; applying adecorative arrangement of lines on the one or more block surfaces;etching out the decorative arrangement of lines to create simulatedmortar lines on the one or more block surfaces; smoothing the one ormore block surfaces without removing the etched decorative arrangementof lines; and finishing the one or more block surfaces to form afinished block segment of simulated masonry faces on the one or moreblock surfaces.
 2. The process as claimed in claim 1 wherein thesimulated mortar lines displayed on all block surfaces extendconsistently to adjacent block surfaces.
 3. The process as claimed inclaim 1 wherein the block material is wood.
 4. The process as claimed inclaim 2 wherein the block material is wood.
 5. The process as claimed inclaim 1 further comprising the steps of: forming additional block piecesof varying sizes having one or more surfaces; applying decorativearrangements of lines to create simulated mortar lines on the one ormore surfaces; smoothing the one or more block surfaces without removingthe etched decorative arrangements of lines; and finishing the one ormore block surfaces to form a finished block with simulated masonryfaces on the one or more block surfaces.
 6. The process as claimed inclaim 5 wherein the simulated mortar lines displayed on all blocksurfaces extend consistently to adjacent block surfaces.
 7. The processas claimed in claim 5 wherein the block material is wood.
 8. The processas claimed in claim 6 wherein the block material is wood.
 9. A blockmade by the process set forth in claim
 1. 10. A block made by theprocess set forth in claim
 5. 11. The process as claimed in claim 1wherein the block material is plastic.
 12. The process as claimed inclaim 5 wherein the block material is plastic.
 13. A process of makingbuilding and training blocks having simulated masonry faces comprisingthe steps of: forming a unit block having one or more surfaces from alarger segment of material; applying a decorative arrangement of lineson the one or more unit block surfaces; etching out the decorativearrangement of lines to create simulated mortar lines on the one or moreunit block surfaces; smoothing the one or more unit block surfaceswithout removing the etched decorative arrangement of lines; andfinishing the one or more unit block surfaces to form a finished unitblock of simulated masonry faces on the one or more unit block surfaces.14. The process as claimed in claim 13 wherein the simulated mortarlines displayed on all unit block surfaces extend consistently toadjacent unit block surfaces.
 15. The process as claimed in claim 13wherein the unit block material is wood.
 16. The process as claimed inclaim 13 wherein the unit block material is wood.
 17. The process asclaimed in claim 13 further comprising the steps of: forming additionalunit block pieces of varying sizes having one or more surfaces; applyingdecorative arrangements of lines to create simulated mortar lines on theone or more surfaces; smoothing the one or more unit block surfaceswithout removing the etched decorative arrangements of lines; andfinishing the one or more unit block surfaces to form finished unitblocks with simulated masonry faces on the one or more unit blocksurfaces.
 18. The process as claimed in claim 17 wherein the simulatedmortar lines displayed on all unit block surfaces extend consistently toadjacent unit block surfaces.
 19. The process as claimed in claim 17wherein the unit block material is plastic.
 20. A unit block made by theprocess set forth in claim
 13. 21. A unit block made by the process setforth in claim
 13. 22. The process as claimed in claim 18 wherein theunit block material is plastic.